Modular system and method for material storage and conveying

ABSTRACT

A modular system for material storage and conveying having a layered storage section with two or more storage layers having conveyors, the layered storage section being associated with a load section and a delivery section having their own conveyors at each end of the layered storage section, and elevators that can selectively position the load and delivery section at operational heights of the conveyors of the layered storage section.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation and claims the benefit of U.S.Non-Provisional application Ser. No. 16/041,692, filed Jul. 20, 2018,which is hereby incorporated by reference, to the extent that it is notconflicting with the present application.

BACKGROUND OF INVENTION 1. Field of the Invention

The invention relates generally to storage and conveyor systems andmethods and more particularly to systems and methods for achieving bothhorizontal storage and bidirectional reciprocal conveying.

2. Description of the Related Art

Businesses often need to store and move a number of stacked materialsfor commercial, manufacturing and/or warehousing purposes. Materialstorage systems are commonly designed to store materials vertically,using shelf-like systems. These vertical storage systems require spaceswith high ceiling height to be installed, thus limiting businesses toonly choose buildings with sufficient ceiling height or at leastbuildings that have areas with sufficient ceiling height. Installingstorage systems in spaces with high ceilings can also be inefficient ifthe installation location is a far distance from where the materialneeds to be used.

Also, vertical material storage systems can often only move one materialholding position at a time, which makes exchanging material positionsrequire long cycle times. This limitation could be a very seriousproblem, leading to great inefficiencies, when for example the storagesystem needs to also function as a conveyor to supply raw materials orreceive processed materials of various categories (e.g., metal sheets ofvarious thicknesses) in a manufacturing context (e.g., in metal laserprocessing applications).

Thus, there is a need for a new and improved storage and conveyingsystem and method that address and solve the problems outlined above.

The aspects or the problems and the associated solutions presented inthis section could be or could have been pursued; they are notnecessarily approaches that have been previously conceived or pursued.Therefore, unless otherwise indicated, it should not be assumed that anyof the approaches presented in this section qualify as prior art merelyby virtue of their presence in this section of the application.

BRIEF INVENTION SUMMARY

This Summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This Summary is not intended to identify key aspects oressential aspects of the claimed subject matter. Moreover, this Summaryis not intended for use as an aid in determining the scope of theclaimed subject matter.

In an aspect, the Modular Conveyor and Storage System (MCSS, the system)disclosed herein provides horizontal rather than vertical storage forraw or processed stack materials, thus eliminating the need for highceiling clearance and increasing storage capacity of a facility byexpanding storage in a horizontal direction. In an aspect, central tothe system is a layered storage section. In an embodiment, the layeredstorage section may have two storage levels providing the upper andlower levels of a reciprocating loop. The MCSS has elevator mountedconveyors at both end sections that can transfer pallets that may beloaded with material to and from each level of the center layeredstorage section. The conveyors may use frame mounted pipe rollers toachieve a bidirectional reciprocating motion when transferring pallets.Positioning elevator mounted conveyors at both end sections of the MCSSspeeds up the pallet exchange cycles by allowing multiple pallets tomove simultaneously in a bidirectional reciprocating motion, whichspeeds access to the next required storage position.

In an example, the MCSS may be designed to supply the required rawmaterials to a Cycle Loader, which in turn may feed said raw materialsto a laser processing machine. The MCSS may accomplish this function bypositioning the required material for loading into the laser cuttingmachine by the Cycle Loader. The system may also be extended or modifiedto provide storage for processed (e.g., cut) materials unloaded by theCycle Loader.

The above aspects or examples and advantages, as well as other aspectsor examples and advantages, will become apparent from the ensuingdescription and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

For exemplification purposes, and not for limitation purposes, aspects,embodiments or examples of the invention are illustrated in the figuresof the accompanying drawings, in which:

FIGS. 1a-c illustrate a perspective view of exemplar embodiments of aModular Conveyor and Storage System (MCSS the system) and a materialload frame, according to an aspect.

FIG. 2 illustrates the front elevation view of the MCSS and materialload frame, according to an aspect.

FIGS. 3a-b illustrate an exploded view of the material load lift sectionof the MCSS and a detailed close-up view of the cross support bars,respectively, according to an aspect.

FIG. 4 illustrates the side elevation view of the material load/liftsection and material load frame, according to an aspect.

FIG. 5 illustrates the top view of the material load/lift section andmaterial load frame during the material loading process, according to anaspect.

FIG. 6 illustrates a detailed partial view of the material load/liftsection at the beam release height, according to an aspect.

FIG. 7 illustrates a detailed partial view of the material load/liftsection x-axis location sensor, according to an aspect.

FIG. 8 illustrates a flow chart describing how material may be loadedonto the MCSS.

FIG. 9 illustrates the top view of the CL load/lift section, accordingto an aspect.

FIG. 10 illustrates a perspective view of an example of the MCSS inoperation, with material loaded on two sections, according to an aspect.

FIG. 11 illustrates the perspective view of the MCSS in operation with alaser machine, according to an aspect.

FIGS. 12a-b illustrate a flow chart detailing how a user may operate theMCSS.

DETAILED DESCRIPTION

What follows is a description of various aspects, embodiments and/orexamples in which the invention may be practiced. Reference will be madeto the attached drawings, and the information included in the drawingsis part of this detailed description. The aspects, embodiments and/orexamples described herein are presented for exemplification purposes,and not for limitation purposes. It should be understood that structuraland/or logical modifications could be made by someone of ordinary skillsin the art without departing from the scope of the invention. Therefore,the scope of the invention is defined by the accompanying claims andtheir equivalents.

It should be understood that, for clarity of the drawings and of thespecification, some or all details about some structural components orsteps that are known in the art are not shown or described if they arenot necessary for the invention to be understood by one of ordinaryskills in the art.

Logic as used herein and throughout this disclosure, refers to anyinformation having the form of instruction signals and/or data that maybe applied to direct the operation of a processor. Logic may be formedfrom signals stored in a device memory. Software is one example of suchlogic. Logic may also be comprised by digital and/or analog hardwarecircuits, for example, hardware circuits comprising logical AND, OR,XOR, NAND, NOR, and other logical operations. Logic may be formed fromcombinations of software and hardware.

For the following description, it can be assumed that mostcorrespondingly labeled elements across the figures (e.g., 120 in FIGS.1 and 220 in FIG. 2, etc.) possess the same characteristics and aresubject to the same structure and function. If there is a differencebetween correspondingly labeled elements that is not pointed out, andthis difference results in a non-corresponding structure or function ofan element for a particular embodiment, example or aspect, then theconflicting description given for that particular embodiment, example oraspect shall govern.

FIGS. 1a-c illustrates a perspective view of exemplary embodiments of aModular Conveyor and Storage System (MCSS, the system) 100 and amaterial load frame 140, according to an aspect. As shown in FIG. 1a ,the MCSS 100 may have three main sections: the material load/liftsection (section 110; material load section; load section) 110, thelayered storage section (section 120) 120, and the Cycle Loaderload/lift section (CL load/lift section, section 130; delivery section;material delivery section) 130. As an example, shown in FIGS. 1a, 1c ,2, 3 a, 4, 8, 10, 11, and 12 a-b, the layered storage section 120 hastwo layers for material storage: the upper layer 120 a and the lowerlayer 120 b. The upper layer 120 a is aligned with the upper operationheight and the lower layer 120 b is aligned with the lower operationheight, which are described in greater detail hereinafter, whenreferring to FIG. 4. It should be understood that the number of levelsof the layered storage section 120 can be increased, and withcorresponding modifications to the rest of the system, the modified MCSScan operate in a similar manner to what is described below. As anexample, the MCSS is shown in FIG. 1b with the layered storage section120′ having three levels (i.e., three vertically disposed storage andconveying layers) for material storage and conveying.

In this example, with section 120 having two storage levels, rawmaterial (not shown in FIG. 1) may be loaded onto the MCSS by placing itonto the cross support bars 141 which may rest on the material loadframe 140. It should be noted that, as section 110 and section 130 maybe similarly constructed, raw material can also be loaded onto section130 if the material load frame 140 is placed around section 130 ratherthan section 110. The raw material may then be transferred onto thededicated material pallet (dedicated pallet, material pallet, pallet)102 a by using the material loading process described in greater detailhereinafter when referring to FIG. 8.

As an example, the system 100 may be designed specifically to supply rawmaterials, as will be described in more detail herein, to a CL (CycleLoader) which loads and unloads product for sheet metal laser processingapplications. It should be noted that the system may be extended ormodified to also receive and store cut materials unloaded from a lasermachine via the Cycle Loader or via another method, as describedhereinafter. FIG. 1c illustrates an example of the MCSS with the middlelayered storage section 120″ extended horizontally (i.e., a secondmiddle layered storage section is added as shown). An example of knownCycle Loader is AMS 3015 CL, made by Amada. The Cycle Loader automatesthe load/unload process while the MCSS extends storage capacity of rawand cut materials for the Cycle Loader. Further, the MCSS can alsoassist by positioning the required thickness material for loading intothe laser cutting machine by the Cycle Loader. An example of known lasercutting machine is LCG 3015 AJ, made by Amada. As known in the art,laser processing can entail cutting shapes from large blank metalsheets. Blank sheets are typically stacked on pallets having an overallsize of 1.5×3.0 meters, or 2.0×4.0 meters. Each sheet has typically arange of 0.7 to 25.4 millimeters in thickness.

FIG. 2 illustrates the front elevation view of the MCSS 200 and materialload frame (140, 240), according to an aspect. In the example disclosedherein, the MCSS uses a system of conveyors 206 and elevators 212 and232 to move or exchange material pallets (pallets) 202 a-c, which may beloaded with different categories (e.g., different thicknesses) of rawmaterial, between different sections and/or different operation and loadheights of the MCSS 200. Every section of the MCSS, section 210, 220(having layers 220 a, 220 b) and 230, is equipped with conveyors 206.Conveyors 206 move pallets horizontally between the different sectionsof the MCSS 200. The material load/lift section 210 and the CL load/liftsection 230 are equipped with elevators 212 and 232 that can lift orlower the conveyors of sections 210 and 230. Thus, the elevators 212 and232 can lift or lower a pallet (with or without material) resting atop aconveyor to different load or operation heights. In the exampledisclosed herein, the elevators (212 and 232 cannot move palletshorizontally and the conveyors 206 cannot move pallets vertically. Itshould be noted that, for pallet position exchanges to occur, at leastone of the sections 210, 220 a, 220 b, or 230 must be empty. In otherwords, there must be no pallet (with or without material) resting atopthe conveyor of at least one of sections 210, 220 a, 220 b, or 230. Forexample, as shown in FIG. 2, section 220 b is empty and no pallet (withor without material) is resting atop its conveyor. The processes thatmay be used to move or exchange pallets, load materials, and thedifferent operation and load heights are described in greater detailhereinafter when referring to FIGS. 4, 8, 10, and 12 a-b.

The direction arrows 201 a-g indicate directions in which the load/liftsection 210, the layered storage section 220, and the CL load/liftsection 220 can move material pallets 202 a-c, which may have beenloaded with raw material. Arrow 201 b indicates that section 210 canmove a pallet 202 a vertically between different operation and loadheights of the MCSS 200. Arrows 201 a and 201 c indicate that a palletcan be moved horizontally from section 210 to section 220 (or viceversa) at each operation height corresponding with the two layers/levels220 a,b. Similarly, arrow 201 g indicates that section 230 can move apallet 202 c vertically between different operation and load heights ofthe MCSS 200 and arrows 201 f and 201 h indicate that a pallet 202 c canbe moved horizontally from section 230 to section 220 (or vice versa) ateach operation height corresponding with the two layers/levels 220 a,b.Arrow 201 d indicates a pallet 202 b on the upper storage level 220 acan be moved horizontally at that upper level from section 220 tosection 210 (or vice versa) or from section 220 to section 230 (or viceversa). Similarly, arrow 210 e indicates that a pallet (not shown) onthe lower storage level 220 b can be moved horizontally at the lowerlevel from section 220 to section 210 (or vice versa) when pallet 202 ais lowered by elevator 212, or from section 220 to section 230 (or viceversa).

FIGS. 3a-b illustrate an exploded view of the material load lift section310 of the MCSS 300 and a detailed close-up view of the cross supportbars 341, respectively, according to an aspect.

As shown in FIG. 3a , support lumber 311 a may be attached temporarilyto the raw material (material) 311 with steel banding 311 b to preventbending of the material during the loading process described in greaterdetail when referring to FIG. 8. As an example, the raw material 311 maybe a 2 meter by 4 meter stack of sheet metal. The support lumber may be4×4's (4 inch×4 inch) and is preferably attached as shown to the top ofthe material 311 lengthwise (i.e., across the x-axis of the material)and attached to the bottom of the material 311 widthwise (i.e., acrossthe y-axis of the material). The support lumber 311 a may be attached tothe bottom of the material 311, as shown, at intervals such that thesupport lumber 311 a will fit in between the cross support bars 341which rest atop of the material load frame 340. The support bars 341 maybe held in place on the load frame 340 by placing the bars between thestabilizing brackets (brackets) 344. A close up view of the crosssupport bars 341 is shown in FIG. 3 b.

During the material loading process described in greater detail whenreferring to FIG. 8, the free rollers 342 can allow the position of thematerial to be more easily adjusted by the operator. The support barhandles 343 can allow for the bars 341 to be easily removed during thematerial loading process as it will explain later in this disclosure.The stabilizing brackets 344 may be positioned on the load frame 340such that the cross support bars 341 will fit in the pockets 305 of thededicated pallet 302. Once the material has been loaded onto the MCSS,the material may rest on the pallet 302 which may rest on the conveyor306. The dedicated pallet 302 may be equipped with y-axis and x-axismaterial origin pins (y- and x-axis origin pins, origin pins) (303 a and303 b respectively) to help ensure that the material 311 is alwaysaligned on pallet 302, by for example an operator pushing the material311 against the pins 303 a as well as 303 b. This way, the position ofthe material 311 on pallet 302, x-axis wise as well as y-axis wise, isprecise and known. It should be noted that the x- and y-axis mayoriginate from the corner 380 of the pallet 302.

The conveyor 306 may use pipe rollers (rollers) 307 to transfer thepallet 302 horizontally between different sections of the MCSS 300. Asshown, at both ends of the conveyor 306, the conveyor may be equippedwith x-axis location sensors (x-axis sensors, sensors) 304, which may belaser sensors, to monitor the presence and position of the pallet 302 onthe conveyor 306, as described in greater detail hereinafter whenreferring to FIGS. 7 and 9. Shaft collars (collars) 308 may be attachedto, for example, four of the rollers 307 on each conveyor 306 to providey-axis stabilization of the pallet 302 as described in greater detailwhen referring to FIG. 4. The elevator 312 may lift and lower theconveyor 306 to the various operation and load positions described ingreater detail hereinafter when referring to FIGS. 4, 6, and 8.

FIG. 4 illustrates the side elevation view of the material load/liftsection 410 and material load frame 440, according to an aspect.

The operation heights of the MCSS are the heights at which materialpallets 402 can be transferred between different sections of the MCSS asdescribed in greater detail when referring to FIGS. 2 and 10. In theexample disclosed herein, with the layered storage section (220 of FIG.2) having two storage levels, the MCSS has two operation heights. Theupper operation height 414 is aligned with the upper level (220 a ofFIG. 2) of the layered storage section 220. The lower operation height413 is aligned with the lower level (220 b of FIG. 2) of the layeredstorage section 220. As an example, FIG. 2 shows the material load/liftsection 210 at the upper operation height 414 and shows the CL load/liftsection 230 at the lower operation height 413.

As shown in FIG. 4, the shaft collars 408 may guide the pallet 402 andkeep the pallet 402 aligned during pallet exchanges with respect to they-axis. As shown by an example in FIG. 3a , the shaft collars 308 arefitted around four of the rollers 307. As shown in FIG. 4, the innerdiameter of the collars 408 may be about equal to the diameter of therollers 407, such that the collars may rotate with the rollers. Theouter diameter of the shaft collars 408 may be greater than the diameterof the rollers 407. Thus, the shaft collars 408 may extend past therollers 407 to fit into the y-axis stabilization channels (stabilizingchannels, the channels) 402 b, which may be secured to the bottom of thepallet 402. As the MCSS conveyor transfers the pallet 402 betweensections, the shaft collars 408 can guide the pallet's stabilizingchannels 402 b around the shaft collars 408 of the next section, so thatthe pallet 402 continues to be stabilized.

FIG. 5 illustrates a top view of the material load/lift 510 section andmaterial load frame 540 during the material loading process, accordingto an aspect. In FIG. 5, the material 511 is shown resting atop thecross support bars 541 and the pallet may be at the “material approach”(805 of FIG. 8) or the “material alignment” (807 of FIG. 8) height. Asdescribed in greater detail when referring to FIG. 8, the materialapproach and alignment heights may allow the operator to adjust theposition of the material 511 by moving the material on the free rollers(342 of FIG. 3b ).

As shown in FIG. 3a , the y- and x-axis origin pins (303 a and 303 brespectively) may be located at one of the y- and x-edge of the pallet302. In FIG. 5, it should be noted that the pallet is substantially notshown because it is beneath the material 511. As described whenreferring to FIG. 8, the operator may align the material 511 in thestack origin position (509; 609 in FIG. 6) by pushing the materialagainst the y- and x-axis origin pins (503 a and 503 b, respectively;603 a and 603 b in FIG. 6 until the material is in the stack origin 509position. Material 511 may be at the origin position when the respectiveedges (i.e., left edge and the bottom edge in FIG. 5) of the material511 are in contact with the origin pins 503 a and 503 b, as shown byFIG. 5 and FIG. 9. As an example, the origin pins 503 a and 503 b may bemade of metal and may be removably attached to the pallet, such that theoperator can remove and reposition certain origin pins (e.g., y-axispins) to accommodate different sizes of material (e.g., shorter inlength).

FIG. 6 illustrates a detailed partial view of the material load/liftsection 610 at the beam release height, according to an aspect. The beamrelease height may be used by the operator during the material loadingprocess described when referring to FIG. 8. After the material 611 hasbeen placed at the material origin position 609, the operator may setthe elevator (212 of FIG. 2) to lift the pallet 602 to the beam releaseheight. As shown in FIG. 6, the stabilizing brackets 644 may be attachedto the material load frame (640 in FIG. 6; 340 of FIG. 3a ) such that,when the pallet 602 is at the beam release height, the cross supportbars 641 will fit into the pockets 605 of the pallet 602. It should benoted that, at the beam release height, the bottom 605 a of the pockets605 may touch the bottom 641 a of the support bars 641 and thus, sincethe height of the pockets 605 may be taller than the height of thesupport bars 641, the support bars will preferably no longer contact thematerial 611 when the pallet 602 is at the beam release height. Thus, atthe beam release height, the weight of the material 611 may be fullysupported by the pallet 602 and not be supported by the support bars 641resting on material load frame (340 of FIG. 3a ; 640 in FIG. 6), thusallowing the support bars 641 to be pulled out. The brackets 644, whichare secured to the load frame 640 may also hold the support bars 641 inplace and prevent the support bars 641 from moving or slipping duringsteps 803 through 809 of the material loading process as described whenreferring to FIG. 8.

FIG. 7 illustrates a detailed partial view of one of the x-axis locationsensors 704 on the material load/lift section 710 conveyor 706,according to an aspect. In the example of MCSS disclosed herein, thex-axis location sensors 704 may be laser sensors. Each conveyor (i.e.,conveyor for sections 210, 220 a, 220 b, and 230 of FIG. 2) may beequipped with two x-axis sensors at either end of the conveyor as shownby 304 in FIG. 3a and by 904 in FIG. 9. The distance between the twox-axis sensors (904 of FIG. 9) on the conveyor 906 may preferably beabout equal to the length of the pallet, as depicted with FIG. 9. Thex-axis sensors 704 may be placed on the conveyor 706 in this manner, sothat a pallet origin position of pallet 702 may be determined, which maybe when the laser beam 704 b of each sensor 704 simultaneously hit therespective corner of a pallet 702, as shown in FIG. 7. As described ingreater detail when referring to FIG. 9, the presence of a pallet 702 ona conveyor 706 may be detected by MCSS if the laser beam 704 b of eitherx-axis sensor 704 contacts the edge of a pallet. The manner in which thex-axis sensors help the MCSS to determine the position of a pallet(e.g., if a pallet is completely on one section or in between sections)is described in greater detail when referring to FIG. 9.

FIG. 8 illustrates a flow chart detailing how material may be loadedonto the MCSS, according to an aspect. Before an operator begins to loadmaterial onto the MCSS using the material load frame (340 of FIG. 3a ),it is suggested the operator attach and secure support lumber (311 a ofFIG. 3a ) with steel banding (311 b of FIG. 3a ) to the material (311 ofFIG. 3a ) in the manner disclosed when referring to FIG. 3a . Again,attaching the support lumber (311 a of FIG. 3a ) may prevent thematerial 311 from bending. In the example of the MCSS disclosed herein,the material load frame 140 is placed around the material load/liftsection 110 as shown in FIG. 1.

The material load sequence (802), represented by A (801), may be carriedout by the following exemplary process. First, the operator sets theMCSS controls to manual (step 803), which allows the operator tomanually set elevator (312 of FIG. 3a ) to different operation and loadheights. When the MCSS is set to manual, the elevator 312 preferablyautomatically lowers the pallet (302 of FIG. 3a ) to the lower operationheight (413 of FIG. 4). After the controls are set to manual, theoperator may place the material 311 onto the cross support bars (341 ofFIG. 3a ) and then remove the support lumber 311 a in step 804. As anexample, the material may be placed on the cross support bars 341 with aforklift, as known in the art.

Next, the operator sets the elevator 312 to lift the pallet 302 to the“material approach” height (step 805). At this height, the elevatorlifts the dedicated pallet to a height such that the operator can seethe location of the x- and y-axis origin pins (303 b and 303 a,respectively) attached to the pallet 302 and adjust the position of thematerial (step 806) to ensure it will not collide with the x- andy-origin pins (303 b and 303 a of FIG. 3a , respectively). At step 806,the pallet 302 as well as the origin pins (303 a, 300 b) are beneath thematerial 311 and cannot come into contact with the material.

Once the operator is confident the origin pins (303 a, 303 b) will notcollide with the material 311, the operator sets the elevator 312 tolift the pallet 302 to the “material alignment” height (step 807). Atthis height, the dedicated pallet does not support any of the materialweight but is raised to a height such that the x- and y-origin pins (603b and 603 a of FIG. 6, respectively) protrude past the cross supportbars 641 in a manner similar to that shown in FIG. 6. Step 807 allowsthe operator to align the material (step 808) to the stack originposition (509 of FIG. 5) by pushing the material (511 of FIG. 5) on thefree rollers (342 of FIG. 3b ) until the material is against the originpins (503 a and 503 b of FIG. 5) as shown by FIG. 5.

After the material is aligned at the stack origin position (509 of FIG.5), the operator sets the elevator (312 of FIG. 3a ) lift the pallet(311 of FIG. 3a ) to the “beam release” height (step 809). At thisheight, disclosed when referring to FIG. 6, the dedicated pallet (602 ofFIG. 6) is raised to fully support the weight of the material (611 ofFIG. 6). Now that the weight of the material is fully supported by thepallet (302 of FIG. 3a ) instead of the cross support bars (341 of FIG.3a ) resting on the material load frame, the cross support bars 341 canbe removed by the operator (step 810).

The operator can remove the support bars 341 by gripping the handles(343 of FIG. 3b ) and sliding the support bars 341 out of the pockets(305 of FIG. 3a ) and off the load frame 340. Now that the support bars341 have been removed from the load frame 340, the operator sets theelevator 312 to lower the pallet 302 to the “lower operation” height(step 811). Setting the pallet 302 to the lower operation height (413 ofFIG. 4) lowers the raw material 311 beneath the load frame 340 andallows the operator to place the cross support bars 341 back onto theload frame (step 812), being thus ready for the next raw material load(as shown by 140 and 141 in FIG. 1). The material has now been loadedonto the MCSS and the operator can set the pallet content conditions(step 813). The pallet content conditions may include, but are notlimited to, the size, quantity, and thickness of the material on thepallet. Now that the material loading process is complete, the operatorsets the MCSS controls back to automatic (step 814).

It should be noted that the Machine Controller (e.g., a PLC(Programmable Logic Controller)) tracks each pallet, and therefore thecontents of each pallet, during each motion routine by using the lasersensors as disclosed herein. Exemplary motion routines are disclosedwhen referring to FIG. 10. It should also be noted that the followingstep (step 815) is part of the MCSS operation process and a descriptionof step 815 is included hereinafter in the description when referring toFIGS. 12a -b.

FIG. 9 illustrates the top view of the CL load/lift section 930,according to an aspect. The pallet is substantially not visible in FIG.9 because the material 931, shown at the material stack origin position909, is on top of the pallet. It should be noted that each conveyor(i.e., the conveyors on sections 210, 220 a, 220 b, and 230 of FIG. 2may be equipped with two x-axis location sensors 904 placed at a widthsuch that each sensor is positioned to detect the corner of a pallet asdisclosed when referring to FIG. 7.

Each sensor 904 may be given a specific identifier (e.g., numericidentifier, descriptive identifier, etc.) by the MCSS to allow the MCSSto know the location of each sensor with respect to the rest of the MCSSsystem. For example, the left and right sensors on the materialload/lift section (110 of FIG. 1) conveyor may be given the descriptiveidentifiers “left material sensor” and “right material sensor,”respectively. The left and right sensors on the upper level conveyor ofthe layered storage section (120 a of FIG. 1) may be given theidentifiers “upper left sensor” and “upper right sensor,” respectively.The left and right sensors on the lower level conveyor of the layeredstorage section (120 b of FIG. 1) may be given the identifiers “lowerleft sensor” and “lower right sensor,” respectively. The left and rightsensors 904 on the CL load/lift section 930 conveyor may be given theidentifiers “left CL sensor” and “right CL sensor,” respectively.

Such identifiers could allow the MCSS to determine the location in thesystem of each pallet at any given time, based on the data reported bythe x-axis sensors 904. The data reported by the sensors 904 may relate,for example, whether or not the sensor detects the presence of a palleton a conveyor and whether the pallet is in the pallet origin position.

The presence of a pallet on a conveyor may be detected by the MCSS whenthe laser beams (704 b of FIG. 7) of either the left or the right x-axislocation sensors 904 on said conveyor contact a pallet. Once the MCSSdetermines the presence of a pallet on a conveyor, the position of thepallet on the conveyor may also need to be determined. In other words,the MCSS may need to determine if a pallet is entirely on the conveyor(as shown by FIG. 9), if it is in a pallet origin position, or if thepallet is partially on multiple sections of MCSS.

The position of a pallet on a conveyor and in the MCSS may be determinedin a manner similar to what is described in the following examples. Itshould be noted that the logic used by the MCSS in the below examplesmay be extended to other similar scenarios not listed in the examplesbelow.

EXAMPLE 1

There is only one pallet, referred to as “pallet A,” on the MCSS. Thepallet is entirely on the CL load/lift section conveyor (as shown by 931in FIG. 9). The position of pallet A may be determined by the MCSSbecause both the “left CL sensor” and the “right CL sensor” 904 of theconveyor will report the presence of pallet A to the MCSS. Because thereare no other pallets on the MCSS, no other x-axis location sensors willreport the presence of a pallet to the MCSS. Thus, the MCSS will knowpallet A is entirely on the CL load/lift section (and precisely in thepallet origin position).

EXAMPLE 2

There is one pallet (pallet A) on the MCSS. As shown in FIG. 1, sections110 and 130 are both at the lower operation height. If pallet A ispartially in section 130 and partially in section 120 b, then the “lowerright sensor” and the “left CL sensor” will report the presence of apallet to the MCSS. Because there are no other pallets on the MCSS, noother x-axis location sensors will report the presence of a pallet tothe MCSS. Thus, the MCSS will know pallet A is partially in section 120b and partially in section 130.

EXAMPLE 3

In this example, there are two pallets (“pallet 1021” and “pallet 1031”)on the MCSS, as shown in FIG. 10. If pallet 1021 is entirely on section1020 a (of FIG. 10) and pallet 1031 is entirely on section 1030 (of FIG.10), then the “upper left sensor,” “upper right sensor,” “left CLsensor,” and “right CL sensor” will report the presence of a pallet tothe MCSS. Because there are no other pallets on the MCSS, no otherx-axis location sensors will report the presence of a pallet to theMCSS. Thus, the MCSS will know pallet 1021 is entirely on section 1020 aand pallet 1031 is entirely on section 1030 (and precisely in the palletorigin position.)

EXAMPLE 4

In this example, there are two pallets (“pallet A” and “pallet B”) onthe MCSS. As shown in FIG. 2, section 210 is at the upper operationheight and section 230 is at the lower operation height. If pallet A ispartially on section 210 and partially on section 220 a, then the “rightmaterial sensor” and the “upper left sensor” will report the presence ofa pallet to the MCSS. If pallet B is partially on section 220 b andpartially on section 230, then the “lower right sensor” and the “left CLsensor” will report the presence of a pallet to the MCSS. Because thereare no other pallets on the MCSS in this example, no other x-axislocation sensor will report the presence of a pallet to the MCSS. Thus,the MCSS will know pallet A is partially on section 210 and partially onsection 220 a and will know pallet B is partially on section 220 b andpartially on section 230.

FIG. 10 illustrates a perspective view of an example of the MCSS inoperation, with material loaded on two sections, according to an aspect.Described hereinafter are exemplary scenarios detailing how conveyorsand/or elevators may work as a system to move or exchange palletsbetween different sections and/or operation heights of the MCSS.

It should also be understood that, as stated hereinbefore, MCSSs havingmore than two levels or having horizontally extended two-level storage(FIGS. 1b-c ) may also be similarly used as alternative embodiments, forthe storage, movement, and exchange of pallets, as disclosed herein.

It should also be noted that the pallets described in the followingscenarios may or may not be loaded with raw material. If the palletscontain raw material, it should be understood that the contents of eachpallet may differ. For example, one pallet may be loaded with a stack often 2 meter by 4 meter metal sheets with a thickness of 10.50millimeters and another pallet may be loaded with a stack of fifteen 2meter by 2 meter metal sheets with a thickness of 5.25 millimeters. Asdescribed when referring to FIGS. 12a-b , the operator may set thepallet content conditions after the material has been loaded onto theMCSS.

Scenario 1:

Pallet A is on the material load/lift section at the upper operationheight, pallet B is on the upper level of the layered storage section,the lower level of the layered storage section contains no pallet, andpallet C is on the CL load/lift section at the upper operation height(110, 120 a, 120 b and 130 of FIG. 1, respectively). In this scenario,pallet A will be transferred from section 110 to section 130 in thefollowing steps: (1) section 110 is moved to the lower operation height,(2) pallet A is transferred from section 110 to section 120 b (the lowerlevel of section 120), (3) section 110 is raised to the upper operationheight, (4) pallet B is transferred from section 120 a to section 110and pallet C is transferred from section 130 to section 120 asimultaneously, (5) section 110 and section 130 are lowered to the loweroperation height simultaneously, (6) pallet A is transferred fromsection 120 b to section 130 and pallet B is transferred from section110 to section 120 b simultaneously, (7) finally section 130 can bemoved to the upper operation with pallet A. It should be noted that theabove scenario, and similarly the scenarios below, may be used, forexample, when a particular job requires, at a given time, the materialresting on pallet A to be delivered to the CL Loader 1150 (see FIG. 11).

Scenario 2:

Pallet A is on section 110 at the lower operation height, pallet B is onsection 120 a, 120 b contains no pallet, and pallet C is on section 130at the upper operation height. In this scenario, pallet B will betransferred from section 120 a to section 130 in the following steps:(1) section 130 is lowered to the lower operation height (2) pallet C istransferred from section 130 to section 120 b, (3) section 130 is raisedto the upper operation height, (4) finally, pallet B is transferred fromsection 120 a to section 130.

Scenario 3:

Section 110 contains no pallet at the upper operation height, pallet Ais on section 120 a, pallet B is on section 120 b, and pallet C is onsection 130 at the upper operation height. In this scenario, pallet Bwill be transferred from section 120 b to 130 with the following steps:(1) pallet A is transferred from section 120 a to section 110 and palletC is transferred from section 130 to section 120 a simultaneously, (2)section 130 is lowered to the lower operation height, (3) finally palletB is transferred from section 120 b to section 130.

Scenario 4:

Section 110 contains no pallet at the upper operation height, pallet Ais on section 120 a, pallet B is on section 120 b, and pallet C is onsection 130 at the upper operation height. In this scenario, pallet A istransferred from section 120 a to 130 in the following steps: (1)section 110 and section 130 are lowered to the lower operation heightsimultaneously, (2) pallet B is transferred from section 120 b tosection 110 and pallet C transferred from section 130 to section 120 bsimultaneously, (3) section 130 is raised to the upper operation height,(4) finally pallet A is transferred from section 120 a to section 130.

FIG. 11 illustrates the perspective view of the MCSS in operation with alaser machine according to an aspect. In FIG. 11, the MCSS is shown tobe installed next to a laser machine loader cycle loader (CL, CLmachine, laser machine loader) 1150 and a laser machine (machine, laser)1160. Together, the CL and the laser machine make up the Amada ModuleSystem-Cycle Loader (AMS-CL). The laser machine's loader 1150 may grabmaterial from the CL load/lift section 1130 via a suction frame 1135using suction cups (not shown), place the material onto the shuttletable 1151, and the shuttle table may then feed the material into thelaser machine 1160. As described herein, the pallet having the materialthat is needed at a particular time can be transferred automaticallyfrom any section of the MCSS to section 1130 and then section 1130 canbe raised to a height such that the laser machine loader 1150 can graband feed the material into 1160. It should be noted that the trackingcapability, disclosed herein, enables the MCSS to automatically transferthe required size material resting on a specific pallet to section 1130,and therefore to the CL Loader 1150.

Again, it should be understood that, while the MCSS is primarilydesigned, as described herein, to feed raw materials to a Cycle Loader1150, which in turn may feed said raw materials to a laser machine 1160,the system may be extended or modified to also receive and store cutmaterials unloaded from the laser machine 1160 via the Cycle Loader 1150or via another way.

FIG. 12a-b illustrates a flow chart detailing how a user may operate theMCSS. This exemplary process starts by first powering on the MCSS (step1201). Next, the operator invokes the origin process (step 1202), whichmay be done by pressing a button. The origin process is described bysteps 1202 though 1208 of FIG. 12a . Once the origin process has beeninvoked, the machine (1160 of FIG. 11) and MCSS (1100 of FIG. 11)prepare themselves for operation, or in other words, the statuses areinitialized (step 1204). Once the status is initialized, the status ofeach laser sensor is checked (step 1204). If the sensors are not ok (ornot operational), then an alarm is generated (step 1205) to notify theoperator to correct the fault in the sensor and reset the alarm (step1206). Once the operator corrected the fault and the alarm was reset,the origin process is again invoked (step 1202).

If the sensors are ok, a sequence for detecting and setting the palletpositions begins (step 1207). During this step, the presence and theposition, including pallet origin position of each pallet on eachconveyor are evaluated by the sensors using the methods describedhereinbefore when referring to FIGS. 7 and 9. If the position of any ofthe pallets needs to be adjusted in order to place the pallet in thepallet origin position, the conveyor will attempt to automaticallycorrect the position of the pallet by for example moving the pallethorizontally forward or backward when the pallet extends over twosections. Next, if the pallet origin set (step 1208) is not complete(i.e., the conveyor was unable to correct the position of the pallet),an alarm is generated (step 1209) to notify the operator to correct thefault and reset the alarm (step 1210).

Once the alarm is reset, the sequence for detecting and setting thepallet positions (step 1207) is again initiated. If the pallet originset (step 1208) is completed correctly, then the origin process has beencompleted and a human machine interface (HMI) can display a screen forthe pallet content conditions (step 1211). The pallet content conditionrefers to material setting such as the dimensions, weight, quantity,etc. of the material.

The HMI may display the last registered material settings for theoperator to approve or adjust (step 1212). Once the operator hasapproved or adjusted the material settings as needed, the operator willbe presented with the option to load new material (step 1213). If theoperator does not need to load new material, then the operator may setthe MCSS controls to automatic (step 1214) and the status that the MCSS1100 is “ready” is reported to the AMS-CL (step 1215). If the operatordoes need to load new material, they may do so by using the materialload sequence (step 1218), represented by A (step 1217), the details ofwhich are described hereinbefore when referring to FIG. 8. Once the newmaterial has been loaded onto the MCSS, the status that the MCSS is“ready” is reported to the AMS-CL (step 1215). After the MCSS is readyfor operation, the operator sets up the laser machine 1160 and the CLmachine 1150 (step 1219). Operation of all lines (the MCSS, CL, andlaser machine) will not begin until all line equipment reports a statusof “ready.”

The operator can now select “system start” (step 1216), which triggersthe automatic operation cycle sequence to begin (sequence) (step 1220).This sequence consists of steps 1220 through 1232. For the first step inthe automatic sequence, the AMS-CL selects which pallet contains the rawmaterial it needs to load (step 1221). As described hereinbefore whenreferring to FIG. 8, the AMS-CL may know the location of the palletcontaining the desired raw material with respect to the rest of thesystem because the Machine Controller (PLC) tracks the pallet movementsafter the operator loads raw material, and therefore tracks the materialon said pallet. Next, the AMS-CL calls for said pallet (step 1222) andthe motion routine for moving the selected pallet to the CL load/liftsection is started (step 1223). This motion routine may be one of thescenarios contained in the description for FIG. 10. Then, the MCSS 1100utilizes the x-axis sensors to determine whether or not the palletchange has been completed (step 1224). If the pallet change is notcomplete, and alarm will be generated (step 1226) to notify the operatorto correct the fault and reset the alarm (step 1227). Then, the operatorcan once again select system start (step 1228, 1216) to once again beginthe automatic sequence (step 1220). If the pallet change is completedcorrectly (i.e., desired pallet is in the origin position and in the CLlift/load section 1130, then the CL (1150 of FIG. 11) initiates theloading routine (step 1225) and the laser machine and CL process thematerial (step 1229).

If the job is not complete (i.e., the laser machine needs more rawmaterial to complete the job, then the AMS-CL will select another palletfor raw material loading (step 1221). If the job is complete, then theoperator has the option to run a new job (step 1231). If the operatorchooses to run a new job, then the AMS-CL will select another pallet forraw material loading (step 1221). If the operator does not choose to runa new job, then the automatic operation sequence ends (step 1232).

If at any point the operator needs to load additional material (step1233), such as during the laser machine and CL material processing, theoperator must select “interrupt” (step 1234) to halt the MCSS, CL, andlaser machine processes. Once the processes have been halted, theoperator can proceed to load new raw material using and referring to thematerial load sequence (step 1237) represented by “A” (step 1235). Asbefore in step 1215, the status that the MCSS 1100 is “ready” isreported to the AMS-CL (step 1236) after the operator completes thematerial loading process. It should be noted that it is possible to loadnew material at any time, with some limitations. For example, if thelaser machine and CL is running (i.e., laser machine is cutting sheetsand CL is loading the next sheet based on the scheduler) and there isn'tany empty position on the conveyor to be able to move either backwardsor forwards, it would be needed to interrupt the CL loader in order tobe able to load new position on the conveyor. As another example, if thecutting cycle per sheet metal is long (let's say one hour), it may beenough time to load new pallet with raw material on conveyor, withoutinterrupting the scheduler of automation.

It should be noted that all the processes, routines, sequences andalgorithms described herein can be incorporated in a logic (software,hardware or combination thereof) that can be used to control the MCSSsystem disclosed herein.

It may be advantageous to set forth definitions of certain words andphrases used in this patent document. The term “couple” and itsderivatives refer to any direct or indirect communication between two ormore elements, whether or not those elements are in physical contactwith one another. The term “or” is inclusive, meaning and/or. Thephrases “associated with” and “associated therewith,” as well asderivatives thereof, may mean to include, be included within,interconnect with, contain, be contained within, connect to or with,couple to or with, be communicable with, cooperate with, interleave,juxtapose, be proximate to, be bound to or with, have, have a propertyof, or the like.

Further, as used in this application, “plurality” means two or more. A“set” of items may include one or more of such items. Whether in thewritten description or the claims, the terms “comprising,” “including,”“carrying,” “having,” “containing,” “involving,” and the like are to beunderstood to be open-ended, i.e., to mean including but not limited to.Only the transitional phrases “consisting of” and “consistingessentially of,” respectively, are closed or semi-closed transitionalphrases with respect to claims.

If present, use of ordinal terms such as “first,” “second,” “third,”etc., in the claims to modify a claim element does not by itself connoteany priority, precedence or order of one claim element over another orthe temporal order in which acts of a method are performed. These termsare used merely as labels to distinguish one claim element having acertain name from another element having a same name (but for use of theordinal term) to distinguish the claim elements. As used in thisapplication, “and/or” means that the listed items are alternatives, butthe alternatives also include any combination of the listed items.

Throughout this description, the aspects, embodiments or examples shownshould be considered as exemplars, rather than limitations on theapparatus or procedures disclosed or claimed. Although some of theexamples may involve specific combinations of method acts or systemelements, it should be understood that those acts and those elements maybe combined in other ways to accomplish the same objectives.

Acts, elements and features discussed only in connection with oneaspect, embodiment or example are not intended to be excluded from asimilar role(s) in other aspects, embodiments or examples.

Aspects, embodiments or examples of the invention may be described asprocesses, which are usually depicted using a flowchart, a flow diagram,a structure diagram, or a block diagram. Although a flowchart may depictthe operations as a sequential process, many of the operations can beperformed in parallel or concurrently. In addition, the order of theoperations may be re-arranged. With regard to flowcharts, it should beunderstood that additional and fewer steps may be taken, and the stepsas shown may be combined or further refined to achieve the describedmethods.

If means-plus-function limitations are recited in the claims, the meansare not intended to be limited to the means disclosed in thisapplication for performing the recited function but are intended tocover in scope any equivalent means, known now or later developed, forperforming the recited function.

If any presented, the claims directed to a method and/or process shouldnot be limited to the performance of their steps in the order written,and one skilled in the art can readily appreciate that the sequences maybe varied and still remain within the spirit and scope of the presentinvention.

Although aspects, embodiments and/or examples have been illustrated anddescribed herein, someone of ordinary skills in the art will easilydetect alternate of the same and/or equivalent variations, which may becapable of achieving the same results, and which may be substituted forthe aspects, embodiments and/or examples illustrated and describedherein, without departing from the scope of the invention. Therefore,the scope of this application is intended to cover such alternateaspects, embodiments and/or examples. Hence, the scope of the inventionis defined by the accompanying claims and their equivalents. Further,each and every claim is incorporated as further disclosure into thespecification.

What is claimed is:
 1. A modular system for material storage andconveying comprising: a layered storage section having a plurality ofstorage layers, a first end and a second end opposite the first end, theplurality of storage layers comprising a first storage layer having afirst conveyor disposed at a lower operation height and a second storagelayer having a second conveyor and being disposed above the firststorage layer at an upper operation height, wherein both the firstconveyor and the second conveyor are adapted to convey bidirectionally,between the first end and the second end; a load section extending fromthe first end of the layered storage section and comprising a firstelevator and a third conveyor, the first elevator being adapted to liftthe third conveyor to the upper operation height and lower the thirdconveyor to the lower operation height, wherein the third conveyor isadapted to convey bidirectionally towards and opposite the first end ofthe layered storage section; a delivery section extending from thesecond end of the layered storage section and comprising a secondelevator and a fourth conveyor, the second elevator being adapted tolift the fourth conveyor to the upper operation height and lower thefourth conveyor to the lower operation height, wherein the fourthconveyor is adapted to convey bidirectionally towards and opposite thesecond end of the layered storage section; and wherein the modularsystem is adapted such that the bidirectional and lifting movements arecoordinated to allow selective repositioning of a load from any of thefour conveyors to any other of the four conveyors.
 2. The modular systemfor material storage and conveying of claim 1, wherein each of the fourconveyors comprises two x-axis laser location sensors adapted todetermine the presence and position of a dedicated pallet on theconveyor, including an origin position of the dedicated pallet which iswhen a laser beam of each sensor simultaneously hit x-axis opposingcorners of the dedicated pallet.
 3. The modular system for materialstorage and conveying of claim 2, wherein the x-axis laser locationsensors have a sensor identifier, such that to allow for determining alocation of the dedicated pallet within the modular system at any giventime.
 4. The modular system for material storage and conveying of claim2, wherein the dedicated pallet comprises a stabilization channeldisposed at the bottom of the dedicated pallet and wherein each of thefour conveyors comprises rollers having collars adapted to fit into thestabilization channel and thus provide y-axis stabilization of thededicated pallet.
 5. The modular system for material storage andconveying of claim 1, wherein the plurality of storage layers furthercomprises a third storage layer disposed above the second storage layer.6. The modular system for material storage and conveying of claim 5,wherein the third storage layer has a conveyor.
 7. The modular systemfor material storage and conveying of claim 1, wherein the plurality ofstorage layers further comprises a third storage layer extendinghorizontally from the first storage layer and a fourth storage layerextending horizontally from the second storage layer.
 8. The modularsystem for material storage and conveying of claim 7, wherein the thirdstorage layer and the fourth storage layer each have a conveyor.
 9. Themodular system for material storage and conveying of claim 1, wherein,when a first material pallet is on the third conveyor at the upperoperation height, a second material pallet is on the second conveyor ofthe layered storage section, the first conveyor contains no pallet, anda third material pallet is on the fourth conveyor at the upper operationheight, the modular system is adapted to transfer the first materialpallet from the load section to the delivery section by lowering thethird conveyor to the lower operation height, transferring the firstmaterial pallet from the third conveyor to the first conveyor, liftingthe third conveyor to the upper operation height, transferringsimultaneously the second material pallet from the second conveyor tothe third conveyor and the third material pallet from the fourthconveyor to the second conveyor, lowering simultaneously the thirdconveyor and the fourth conveyor to the lower operation height, andtransferring simultaneously the first material pallet from the firstconveyor to the fourth conveyor and the second material pallet from thethird conveyor to the first conveyor.